Giant GP7636GB-2.0 Operating Instructions/ Repair And Service Manual
- Type
- Operating Instructions/ Repair And Service Manual
Triplex Ceramic
Plunger Pump
Operating Instructions/
Repair and Service
Manual
Model
GP7636GB-2.0
Contents:
Installation Instructions: page 2
Pump Specications: page 3
Torque Specs: page 3
Recommended Spare
Parts List: page 3
Exploded View: page 4
Parts List/Kits page 5
Repair and Service: pages 6-7
Warranty Information: back page
2
INSTALLATION INSTRUCTIONS
Operation and Maintenance
Check oil level prior to starting and ensure trouble-free
water supply.
Oil: Use only 1.7 gallons (6.3 liters) of ISO VG-220
synthetic gear oil. Initial change after 50 hours and then
after every 200 operating hours. If used less than this,
change once per year.
IMPORTANT! When operating in humid areas (or areas
with large temperature uctuations, the oil must be
changed immediately (if condensate or frothy oil occurs
in the crankcase).
IMPORTANT! We recommend that both inlet ports be
used in order to ensure cavitation-free operation and op-
timal suction conditions. If only one connection is use, a
safety margin of 3 feet (1 meter) has to be added to the
required NPSH.
IMPORTANT! If the pump is mounted on a vehicle with
the possibility of unlevelness and/or the pump speed is
between 300 & 500 RPM, the volume of oil should be
1.93 gallons (7.3 liters). To check, put the oil dipstick in
the bore situated next to the eye bolt.
IMPORTANT! The GP7636GBHS-2.4 pumps has a
black arrow on the reduction gear, which shows the pre-
ferred direction of rotation. The pump can be delivered
either with the gear on the left side or right side (when
facing the front of the pump), which eases planning
assembled units with regard to the desired direction or
rotation. In either case, the larger gear wheel must
rotate towards the front-end of the pump.
The preferred/optimal direction of rotation ensures that
the oil is correctly splashed on the crosshead guides via
the motion of the connecting rods, which is a particular
advantage where continuous operation is involved.
The pump can also be run against the recommended
direction of the rotation if operated periodically or at re-
duced pressure. If this is the case, the pump has to be
run in this direction to smoothen the bearing areas. This
is done by a one-time operation at zero pressure for at
least 30 minutes; thereafter, the pressure must be slowly
increased over the next hour to the desired maximum
operating pressure. This should run-in the pump, but
you should also check the oil temperature, which should
not exceed 140 o F (60 oC).
The torque tension on the valve casing nuts (49A) is to be
checked after approximately 200 hours. Please see page
7 for torque values.
IMPORTANT! The service life of the seals is maximized
if a minimal amount of leakage is present. A few drops of
water can drip from each plunger every minute. Leakage
has to be examine every day. If the leakage becomes
excessive (constant dripping), the plunger seals must be
changed.
Safety Rules
The operating instructions must be read and adhered
to before performing any work on the pump or com-
plete assembled unit. No responsibility will be carried
by us for damage to materials or persons caused by
improper handling of our pumps.
Access to the pump is not allowed by unauthorized person-
nel. As safety valve is to be installed in accordance with
the guidelines for liquid spraying units, so that the admis-
sible operating pressure cannot be exceeded by more than
10%. Pumps operating without a safety valve as well as
any excess in temperature or speed limits automatically
voids the warranty. When the pump is in operating, the
exposed shaft side, the driven shaft side and its coupling
must be covered by a protective guard. The plunger area
must also be covered by the protective plate (30). Do not
step onto the protective plate (30 ) or put weight on it.
Before carrying out any maintenance work to the pump or
pump unit, the pressure in the discharge line and pump
must be at zero. Close off the suction line. Disconnect
fuses to ensure that the driving motor cannot accidently
get switched on. Before starting the pump, make sure that
the pump, the cooling system and all parts on the pressure
side of the unit are vented and relled with pressure at
zero.
In order to prevent air or air/water-mixture being absorbed
and cavitation occurring, the pump NPSHR (Net Positive
Suction Head Required) and water temperature must be
adhered to.
Cavitation and/or compression of gases lead to uncon-
trollable pressure kicks, which can ruin the pump and
unit parts and also be dangerous to the operator or
anyone standing nearby.
Giant plunger pumps are only suitable for pumping fresh
clean water.
3
U.S. Metric
Maximum Volume*...........................................................36.4 GPM .................................137.7 L/min
Maximum Discharge Pressure* .......................................3800 PSI ..........................................262 Bar
Maximum Speed* ...................................................................................................................900 RPM
Inlet Pressure ..................................................................-4.35 to 145 PSI......................-0.3 to 10 Bar
Plunger Diameter.............................................................1.4” ....................................................36 mm
Plunger Stroke .................................................................2.28” ..................................................58 mm
Crankshaft Bore....................................................................................... SAE-C Spline 14T 12/24 DP
Shaft Rotation ....................................................................................... Top of pulley towards manifold
Temperature of Pumped Fluids .......................................140 oF ..................................................60 oC
Inlet Ports .......................................................................................................................(2) 1 1/4” NPT
Discharge Ports .................................................................................................................(2) 3/4” NPT
Weight .............................................................................476 lbs. ..............................................216 kg
Crankcase Oil Capacity ...................................................2.1 gallons ........................................... 8.0 L
Fluid End Material..........................................................................................................Stainless Steel
GP7636GB-2.0 Pump Specications
Consult the factory for special requirements that must be met if the
pump is to operate beyond one or more of the limits specied above.
HORSEPOWER RATINGS:
The rating shown are the power requirements
for the pump. Gas engine power outputs must
be approximately twice the pump power require-
ments shown above.
We recommend a 1.15 service factor be speci-
ed when selecting an electric motor as the
power source.
To compute specic pump horsepower require-
ments, use the following formula:
GPM X PSI
1450
hp =
*Intermittent duty only
GP7636GB-2.0 TORQUE SPECIFICATIONS
Position Item# Description Torque Amount
24A 07616 Fitting Screw 30 ft-lbs. (40 Nm)
36A 07667 Plunger Base 33 ft.-lbs. (45 Nm)
36C 07664 Tensioning Screw 30 ft.-lbs. (40 Nm)
49A 13160 Nut 103 ft.-lbs. (140 Nm)
58C 07702 Hexagon Screw 155 ft.-lbs. (210 Nm)
Preventative Maintenance Check-List & Recommended Spare Parts List
Check Daily Weekly 50hrs Every Every Every
500 hrs 1500 hrs 3000 hrs
Oil Level/Quality X
Oil Leaks X
Water Leaks X
Belts, Pulley X
Plumbing X
Recommended Spare Parts
Oil Change (1 Gal) p/n 1154 X X
Plunger Packing Kits (1 kit/ X
pump) (See page 5 for kit list)
Valve Assembly Kit (1 kit/ X
pump) (See page 5 for kit list)
Oil Seal Kit (1 kit/pump) X
(See page 5 for kit list)
4
Exploded View - GP7636GB-2.0 Pumps
5
GP7636GB-2.0 PARTS LIST
Plunger Packing Kits - # 09544
Item Part # Description Qty.
38A 13141 O-Ring, Seal Case 6
38B 13142 Support Ring 6
39A 13291 Grooved Ring 3
42 06796 V-Sleeve 6
GP7636GB-2.0 PUMP REPAIR KITS
Valve Assembly Kit - #09520
Item Part # Description Qty.
51A 12056 Support Ring 6
51B 07354 O-Ring 6
51C 13131 Inlet Valve Seat 3
51D 13130 Valve Plate 6
51E 07062-0100 Valve Spring 6
52C 13149 Discharge Valve Seat 3
58A 07700 O-Ring 3
58B 07693 Support Ring 3
Oil Seal Kit - # 09221
Item Part # Description Qty.
32 07624 Radial Shaft Seal 3
33A 07627 O-Ring 3
ITEM PART DESCRIPTION QTY.
1 05769 Crankcase 1
2 13000 Oil Filler Plug Assembly 1
8 07603 Oil Dip Stick 1
9 01009 O-Ring, Dip Stick 1
12 07109 Drain Plug 8
13 06272 Copper Seal for 12 8
14 05770 Bearing Cover 1
14A 12204 O-Ring 4
15 05771 Radial Shaft Seal 1
16 05772 O-Ring 2
17 05642 Inner Hexagon Screw 4
18 05039 Spring Ring 4
20 05773 Taper Roller Bearing 2
20A 05774 Fitting Disc (Shim) 1-5
21 05645 Shaft Guard Holder 1
21A 05646 Shaft Guard 1
22 04517 Crankshaft 1
23 05776 Key 1
24 05777 Connecting Rod Assembly 3
25 05778 Crosshead Assembly 3
28 05779 Crosshead Pin 3
29A 07408 Hexagon Nut 1
29B 05383 Bracket 2 f. Cooling Hose 2
29C 05662 Fixing Bracket 1
29D 05381 Bracket 2 f. Cooling Hose 1
30 07619 Cover Plate 1
30A
07225-0100
Hexagon Screw 9
30B 13136 Grommet 4
30C 05053 Disc 8
30D 13154 Cover 1
31 07623 Eye Bolt 1
32 07624 Radial Shaft Seal 3
33 07626 Seal Retainer 3
33A 07627 O-Ring for Seal Retainer 3
33B 07628 Circlip for 33 3
33C 07249 Fitting Disc 3
34 13137 Oil Scraper (Flinger) 3
36 06792 Plunger Assembly (36A-36D) 3
36A 07667 Plunger Connection 3
36B 06793 Plunger Pipe 3
36C 07664 Tensioning Screw 3
36D 07665 Copper Ring 3
38 06093 Seal Case 3
38A 13141 O-Ring, Seal Case 6
38B 13142 Support Ring 6
39 06794 Seal Sleeve 3
39A 13291 Grooved Ring 3
41 06795 Pressure Ring 3
42 06796 V-Sleeve 6
43 06797 Sleeve Support Ring 3
45 06098 Tension Spring 3
49 13159 Stud Bolt 8
49A 13160 Hexagon Nut 8
50 06798 Valve Casing 1
50A 13162 Centering Stud 2
51 13146 Inlet Valve Assembly 3
51A 12056 Support Ring 3
51B 07354 O-Ring 3
51C 13131 Inlet Valve Seat 3
ITEM PART DESCRIPTION QTY.
51D 13130 Valve Plate 3
51E 07062-0100 Valve Spring 3
51F 13147 Spacer Pipe 3
52 13148 Discharge Valve Assembly 3
52A 12056 Support Ring 3
52B 07354 O-Ring 3
52C 13149 Discharge Valve Seat 3
52D 13130 Valve Plate 3
52E 07062-0100 Valve Spring 3
52F 13147 Spacer Pipe 3
57 06078 Compression Spring 3
58 07699 Plug 3
58A 07700 O-Ring 3
58B 07693 Support Ring 3
58C 07702 Hexagon Screw 12
59 07703 Plug, 3/4” 1
59A 07704 Copper Ring for 59 1
60 04366 Plug, 3/4” NPT 1
61 12251 Plug, 1-1/4” NPT 1
62 07662 Tool for valve assembly
(not shown) 1
68 05782 Bottom Casing for Gear 1
69 05783 Top Casing for Gear 1
70 05784 Gear Seal 1
71 05785 Centering Ring 1
72A/B 04534 Gear Wheel Set, i=2.0 1
73 13243 Fitting Key 1
74 05787 Self-Aligning Roller Bearing 1
75 05700 Cylinder Roller Bearing 1
76 07117 Fitting Disc 1-5
77 05701 Radial Shaft Ring 1
78 05665 Cylindrical Pin 4
80 05790 Spacer Ring 1 for Gear 1
81 05791 Spacer Ring 2 for Gear 1
82 05802 Fixing Plate for Gear 1
83 13358 Hexagon Screw 1
84 05792 Hexagon Socket Screw 7
85 05702 Hexagon Socket Screw 8
86 07159 Washer 8
90 04157 Oil Cooler Assembly 1
K1 05797 Cooling Vane Plate 1
K2 05798 Seal for Gear Cover 2
K3 05799 Gear Cover 1
K4 05029 Hex Head Countersunk
Screw 4
K5 05800 Hexagon Socket Screw 8
K6 06725 Washer 8
K7 05755 Connection for Oil Cooler 1
K8 06272 Copper Seal 6
K9 07109 Plug, 1/2” BSP 2
K10 05031 Reducing Nipple 4
K11 05032 U-Joint Connector with Nut 3 or 4
K12 05033 Tube for Cooler 2
K13 05402 Hose Clamp 4
K14 05403 Hose Guard 2
K16 05405 Flat Gasket 4
K17 08280 Washer, GP7655GB Only 4
K18 04158 Hexagon Socket Screw 4
6
GP7636GB-2.0 REPAIR INSTRUCTIONS
NOTE: Always take time to lubricate all metal and non-metal parts with a light lm of oil before reassembling.
This step will help ensure proper t, at the same time protecting the pump non-metal parts (elasto-
mers) from cutting and scoring.
1. Loosen screws (58C), take
plugs (58) out of valve cas-
ing with two screws.
2. Take out tension spring (57)
and complete valve (51)
using either valve tool (part
#07662) or stud bolt M16.
3. Valve seats (51C and 52C)
are pressed out of spacer
pipe (51F) by hitting the
valve plate (51D/52D) with
a bolt.
4. Check surfaces of valve plate (51D/52D), valve seat (51C/52C),
O-rings (51B, 58A), and support rings (51A, 58B) and replace
worn parts.
5. When reassembling: The suc-
tion valve seat (51C) is 1mm
smaller in diameter than the
discharge valve seat (52C).
Suction valve seats are
marked “S” and always have
to be installed rst. Discharge
valve seats are marked “P”
and are always tobe installed
on top of suction valve. Plugs
(58) are to be tensioned down
evenly with screws (58C) in
a crosswise pattern at 155
ft-lbs. (210 Nm).
51F 51E/52E 51D/ 51B/52B 51A/ 51C/52C
52D 52A
PS
6. Loosen nuts (49A) 7. Remove pump head.
8. Separate plunger (36A)
from crosshead (25) by
means of one open-end
wrench (M36).
9. Pull seal sleeves (39) out of
their ttings in the crank-
case. Take seal case (38)
out of seal sleeve (39).
7
GP7636GB-2.0 REPAIR INSTRUCTIONS
11. Check plunger pipe (36B) and seals (39A, 42) for wear. When replacing plunger pipe (36B), tighten tensioning
screw (36C) to 30 ft-lbs (40 NM). If o-rings (38A) or support rings (38B) are damaged, replace with new parts.
38A 38B 38 38B 38A 36
10. Take tension spring (45) and seal pack (41, 42, 43) out of seal sleeve. Take a thin screw driver and pry out
the grooved ring (39A). Note: This seal (39A) will not be reusable, so replace with a new part. For the
seal-pack (41-43), remove with either a socket wrench or use a screw driver to push against the rear lip of
the pressure ring (41) or v-sleeves (42). You will need to remove seals evenly out of the seal sleeve (39). Be
careful not to score the sleeve or metal parts (41 & 43).
39A 39 41 42 43 45
CAUTION: Don’t loosen the 3 plunger (36) before the valve casing has been removed otherwise the plunger
(36) could hit against the spacer pipe (51F) when the pump is being turned.
Seal life can be increased if the pretensioning allows for a little leakage. This assists lubrication
and keeps the seals cool. It is therefore not necessary to replace seals before the leakage be-
comes too heavy and causes output and operating pressure to drop.
MOUNTING VALVE CASING
NOTE: Replace worn parts; grease seals with silicone before installing.
12. Check O-rings (38A) and support rings (38B) on seal case (38). Clean surfaces of seal sleeves in gear box
and sealing surfaces of valve casing. Reassemble seal sleeve (39) by placing plunger (36) in seal sleeve;
place pressure ring (41), v-sleeves (42), sleeve support ring (43), and tension spring (45) over plunger (36).
Place the seal case onto the seal sleeve and press into the crankcase, making sure that the weep hole on the
seal sleeve is facing down. Tighten tensioning screw (36C) to 30 ft.-lbs. (40 Nm). Tighten plunger connection
(36A) onto crosshead (25) with an open end wrench (M36) to 33 ft-lbs. (45 Nm).
13. Push valve casing carefully onto O-rings of seal case and centering studs (50A). Tighten nuts (49A) to 103
ft-lbs. (140 Nm).
TO DISASSEMBLE GEAR
14. Take out plunger (36) and seal sleeves (39) as described above. Drain oil.
15. After removing the circlip ring (33B), lever out seal retainer (33) with a screw driver. Check seals (32,32A,33A)
and surfaces of crosshead.
16. Remove crankcase cover (4). Loosen inner hexagon screws on the connecting rods (24) and push con rod
halves as far into the crosshead guide as possible.
IMPORTANT: Connecting rods are marked for identication. Do not twist con rod halves. Con Rod is to be rein-
stalled in the same position on shaft journals.
17. Check surfaces of connecting rod and crankshaft (22). Take out bearing cover (14) to one side and push out
crankshaft taking particular care that the connecting rod (24) doesn’t bend.
CAUTION: Seal (32A) must always be installed so that the seal-lip on the inside diameter faces the oil. Reas-
semble in reverse order: Regulate axial bearing clearance - minimum 0.1mm, maximum 0.15mm-by means of
tting disc (20A). The crankshaft (22) should turn easily with little clearance. Tighten tting screws (24A) to 30
ft.-lbs. (40 Nm).
CAUTION: Connecting rod (24) must have some sidewise movement at the stroke journals.
07/18 GP7636GB-2.0.indd
GIANT INDUSTRIES, INC. 900 N. Westwood Ave., Toledo, Ohio 43607
Phone: (419)-531-4600 FAX (419)-531-6836, www.giantpumps.com
Copyright 2018 Giant Industries, Inc.
GIANT INDUSTRIES LIMITED WARRANTY
Giant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from
defects in workmanship and material as follows:
1. For portable pressure washers and self-serve car wash applications, the discharge
manifolds will never fail, period. If they ever fail, we will replace them free of charge.
Our other pump parts, used in portable pressure washers and in car wash applications,
are warranted for ve years from the date of shipment for all pumps used in NON-
SALINE, clean water applications.
2. One (1) year from the date of shipment for all other Giant industrial and consumer
pumps.
3. Six (6) months from the date of shipment for all rebuilt pumps.
4. Ninety (90) days from the date of shipment for all Giant accessories.
This warranty is limited to repair or replacement of pumps and accessories of which
the manufacturer’s evaluation shows were defective at the time of shipment by the manufacturer.
The following items are NOT covered or will void the warranty:
1. Defects caused by negligence or fault of the buyer or third party.
2. Normal wear and tear to standard wear parts.
3. Use of repair parts other than those manufactured or authorized by Giant.
4. Improper use of the product as a component part.
5. Changes or modications made by the customer or third party.
6. The operation of pumps and or accessories exceeding the specications set forth
in the Operations Manuals provided by Giant Industries, Inc.
Liability under this warranty is on all non-wear parts and limited to the replacement or repair of those
products returned freight prepaid to Giant Industries which are deemed to be defective due to work-
manship or failure of material. A Returned Goods Authorization (R.G.A.) number and completed
warranty evaluation form is required prior to the return to Giant Industries of all products under war-
ranty consideration. Call (419)-531-4600 or fax (419)-531-6836 to obtain an R.G.A. number.
Repair or replacement of defective products as provided is the sole and exclusive remedy provided
hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES,
OR EXPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR
INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT.
THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR
REPRESENTATION, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR-
RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH
WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
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